US20190389100A1 - Injection molding device and injection method thereof - Google Patents
Injection molding device and injection method thereof Download PDFInfo
- Publication number
- US20190389100A1 US20190389100A1 US16/132,452 US201816132452A US2019389100A1 US 20190389100 A1 US20190389100 A1 US 20190389100A1 US 201816132452 A US201816132452 A US 201816132452A US 2019389100 A1 US2019389100 A1 US 2019389100A1
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- US
- United States
- Prior art keywords
- injection molding
- mold
- mold cavity
- lower mold
- mold base
- Prior art date
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Links
- 238000001746 injection moulding Methods 0.000 title claims abstract description 53
- 238000002347 injection Methods 0.000 title claims abstract description 21
- 239000007924 injection Substances 0.000 title claims abstract description 21
- 238000000034 method Methods 0.000 title claims description 10
- 239000011148 porous material Substances 0.000 claims abstract description 28
- 239000007789 gas Substances 0.000 claims description 58
- 239000002994 raw material Substances 0.000 claims description 24
- 238000001816 cooling Methods 0.000 claims description 14
- 230000008569 process Effects 0.000 claims description 6
- 238000010146 3D printing Methods 0.000 claims description 3
- 229910000831 Steel Inorganic materials 0.000 claims description 3
- 239000010959 steel Substances 0.000 claims description 3
- 238000005187 foaming Methods 0.000 description 9
- 238000010586 diagram Methods 0.000 description 5
- 239000007788 liquid Substances 0.000 description 4
- 239000003795 chemical substances by application Substances 0.000 description 3
- 239000006260 foam Substances 0.000 description 3
- 238000004519 manufacturing process Methods 0.000 description 3
- 239000000203 mixture Substances 0.000 description 3
- CURLTUGMZLYLDI-UHFFFAOYSA-N Carbon dioxide Chemical compound O=C=O CURLTUGMZLYLDI-UHFFFAOYSA-N 0.000 description 2
- 239000004433 Thermoplastic polyurethane Substances 0.000 description 2
- 230000008859 change Effects 0.000 description 2
- 239000000110 cooling liquid Substances 0.000 description 2
- 238000005507 spraying Methods 0.000 description 2
- 229920002803 thermoplastic polyurethane Polymers 0.000 description 2
- IJGRMHOSHXDMSA-UHFFFAOYSA-N Atomic nitrogen Chemical compound N#N IJGRMHOSHXDMSA-UHFFFAOYSA-N 0.000 description 1
- OKTJSMMVPCPJKN-UHFFFAOYSA-N Carbon Chemical compound [C] OKTJSMMVPCPJKN-UHFFFAOYSA-N 0.000 description 1
- 229910052799 carbon Inorganic materials 0.000 description 1
- 229910002092 carbon dioxide Inorganic materials 0.000 description 1
- 239000001569 carbon dioxide Substances 0.000 description 1
- 238000007796 conventional method Methods 0.000 description 1
- 230000002950 deficient Effects 0.000 description 1
- 238000005516 engineering process Methods 0.000 description 1
- 239000012530 fluid Substances 0.000 description 1
- 210000001161 mammalian embryo Anatomy 0.000 description 1
- 239000000463 material Substances 0.000 description 1
- 238000012986 modification Methods 0.000 description 1
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- 239000012778 molding material Substances 0.000 description 1
- JCXJVPUVTGWSNB-UHFFFAOYSA-N nitrogen dioxide Inorganic materials O=[N]=O JCXJVPUVTGWSNB-UHFFFAOYSA-N 0.000 description 1
- 239000004033 plastic Substances 0.000 description 1
- 229920003023 plastic Polymers 0.000 description 1
- 230000009467 reduction Effects 0.000 description 1
- 230000035939 shock Effects 0.000 description 1
- 239000007921 spray Substances 0.000 description 1
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Chemical compound O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 description 1
Images
Classifications
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- B29C44/34—Auxiliary operations
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- B29C44/38—Feeding the material to be shaped into a closed space, i.e. to make articles of definite length
- B29C44/42—Feeding the material to be shaped into a closed space, i.e. to make articles of definite length using pressure difference, e.g. by injection or by vacuum
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- B29C33/44—Moulds or cores; Details thereof or accessories therefor with means for, or specially constructed to facilitate, the removal of articles, e.g. of undercut articles
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- B29C44/04—Shaping by internal pressure generated in the material, e.g. swelling or foaming ; Producing porous or cellular expanded plastics articles for articles of definite length, i.e. discrete articles consisting of at least two parts of chemically or physically different materials, e.g. having different densities
- B29C44/0415—Shaping by internal pressure generated in the material, e.g. swelling or foaming ; Producing porous or cellular expanded plastics articles for articles of definite length, i.e. discrete articles consisting of at least two parts of chemically or physically different materials, e.g. having different densities by regulating the pressure of the material during or after filling of the mould, e.g. by local venting
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- B—PERFORMING OPERATIONS; TRANSPORTING
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- B29C45/00—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
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- B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
- B29K2105/00—Condition, form or state of moulded material or of the material to be shaped
- B29K2105/04—Condition, form or state of moulded material or of the material to be shaped cellular or porous
- B29K2105/041—Microporous
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Definitions
- the present disclosure relates to an injection molding device.
- the injection molding machine also known as an EVA injection machine or an injection machine, is a device or a machine that is mainly used to manufacture a plastic product.
- the injection molding machine is composed of two main parts: a clamping unit an injection unit.
- thermoplastic polyurethanes (TPU) raw materials must be subjected to a baking process to remove moisture contained. Water vapor will cause bubbles to be generated on the surface of a finished product when the raw materials are formed in the mold. Physical foaming will also have the same situation, which will result in a rough surface of a finished product.
- the initial embryo after foaming is subjected to surface processing to overcome the aforementioned problems, thereby increasing the process steps.
- the abovementioned injection molding method allows the raw materials to be injected into the mold to be heated and foamed.
- the gas pressure in the mold is not consistently controlled so that the gas and the raw materials cannot be completely fused/merged or separated during the faming process, thereby causing the finished product to have the problems of partial hard blocks and uneven foaming.
- this will cause incomplete filling and foaming porosity, which are commonly known as the entrapped air phenomenon. Such phenomenon will increase the defective rate of the finished products.
- the conventional methods are to spray the release agent in the mold to prevent the molding material from adhering to the inner wall of the mold.
- a removing device for taking out the finished products from the mold is provided.
- the release agent may remain on the inner wall of the mold, and will affect the subject process steps. Further, the spraying and the subsequent clearing operations are required. As such, how to provide a better injection molding device and a better injection molding method thereof has become one of the important issues.
- Another object of the present disclosure is to provide an injection molding method, so that the raw materials do not need to be dried and the time for front work can be saved.
- the present disclosure provides an injection molding device, an upper mold base, having an upper mold base groove and an injection port, wherein the injection port is connected to the injection molding machine; an upper mold, arranged inside the upper mold base groove and having an ejection port, a gasket groove and a gasket, wherein the ejection port is connected to the injection port; a lower mold base, operatively aligning or separating from the upper mold base and having a lower mold base groove and at least one gas passage, wherein the at least one gas passage allows gas to enter and exit; and a lower mold, arranged inside the lower mold base groove and having a mold cavity, wherein the lower mold together with the lower mold base aligns and separates from the upper mold together with the upper mold base, the lower mold includes at least one shaped air path that is connected to the mold cavity and the at least one gas passage, the lower mold is a porous material, the porous material enables the lower mold to have a plurality of pores; when the lower mode base is aligned with the upper mold
- the present disclosure further includes a control device, controlling an amount and timing of incoming and outgoing gases and adjusting the pressure in the mold cavity, wherein the injection molding machine is controlled by the control device to control a flow of the raw material into the mold cavity.
- a control device controlling an amount and timing of incoming and outgoing gases and adjusting the pressure in the mold cavity, wherein the injection molding machine is controlled by the control device to control a flow of the raw material into the mold cavity.
- the upper mold is a porous material; the porous material enables the upper mold to have a plurality of pores.
- the at least one shaped air path of the lower mold is formed by three-dimensional printing or processed by a gas permeable steel.
- the at least one shaped air path includes at least one main air duct and a plurality of secondary air ducts
- the at least one main air duct is disposed around the mold cavity and the bottom thereof, and communicates with the at least one gas passage
- each of the plurality of secondary air ducts is arranged at the intervals between the main air duct and the mold cavity, and one end of each of the plurality of secondary air ducts communicates with the main air duct, the other end thereof is connected to the mold cavity.
- the gasket groove is disposed around the ejection port, the gasket is disposed in the gasket groove, one side of the gasket is fitted to the bottom of the gasket groove, and another side of the gasket is attached to the lower mold when the lower mold base is aligned with the upper mold base.
- the upper mold base and the lower mold base further include at least one cooling waterway.
- a valve for preventing backflow of the gas is provided between the control device and the at least one gas passage.
- the present disclosure further includes a pressure measuring unit, sensing the internal pressure of the mold cavity and is electrically connected to the control device.
- FIG. 1 shows an exploded perspective view of an injection molding device according to a preferred embodiment of the present disclosure.
- FIG. 2 shows a schematic diagram of the injection molding device according to the preferred embodiment of the present disclosure.
- FIG. 3 shows a partial enlarged schematic diagram of the injection molding device shown in FIG. 2 according to the preferred embodiment of the present disclosure.
- FIG. 4 shows a stereoscopic diagram of a lower mold of the injection molding device according to the preferred embodiment of the present disclosure.
- FIG. 5 shows an A-A sectional view of FIG. 2 according to the preferred embodiment of the present disclosure.
- FIG. 6 shows a B-B sectional view of FIG. 2 according to the preferred embodiment of the present disclosure.
- FIG. 7 shows a block diagram of the injection molding device according to the preferred embodiment of the present disclosure.
- FIG. 8 shows a flow chart of an injection molding method according to the preferred embodiment of the present disclosure.
- an injection molding device of the present disclosure for use with an injection molding machine mainly includes an upper mold base 10 , an upper mold 20 , a lower mold 30 and a lower mold base 40 .
- the upper mold base 10 is a first matching surface 104 .
- the first matching surface 104 has an upper mold base groove 101 .
- Another side of the upper mold base 10 has an injection port 102 .
- the injection port 102 of the upper mold base 10 is connected to one end of the injection molding machine 52 .
- the upper mold 20 is arranged inside the upper mold base groove, and has two ejection ports 201 , a gasket groove 202 and a gasket 203 . Each of the ejection ports 201 is connected to the injection port 102 .
- the upper mold 20 has two ejection ports, but they are not limited to the present disclosure.
- the material of the upper mold 20 is a porous material and the porous material enables the upper mold 20 to have a plurality of pores.
- the upper mold base 10 also includes at least one cooling waterway 103 and the upper mold 20 also includes at least one cooling circuit that is connected to the at least one cooling waterway 103 of the upper mold base 10 .
- the at least one cooling waterway 103 is connected to a liquid device.
- the internal cooling liquid (not shown) is circuited inside the at least one cooling waterway and the at least one cooling circuit, thereby maintaining the upper mold base 10 and the upper mold 20 within a predetermined temperature value.
- the upper mold 20 includes a gasket groove 202 that is arranged around the ejection port 201 .
- a gasket 203 is disposed inside the gasket groove 202 .
- One side of the gasket 203 is attached to the bottom of the gasket groove 202 .
- the second matching surface 404 is a second matching surface 404 , and operatively aligns or separates from the first matching surface 104 of the upper mold base 10 .
- the second matching surface 404 has a lower mold base groove 401 and at least one gas passage 402 .
- the at least one gas passage is used for gas (not shown) in and out of a gas device 51 .
- the lower mold 30 is a porous material. The porous material enables the lower mold 30 to have a plurality of pores.
- the lower mold 30 is aligned with and is separated from the upper mold 20 .
- the lower mold 30 is arranged inside the lower mold base groove 401 .
- the lower mold 30 includes a mold cavity 301 and at least one shaped air path 302 .
- the present disclosure does not limit the manner in which the at least one shaped air path 302 of the lower mold 30 is formed.
- the at least one shaped air path 302 of the lower mold is formed by three-dimensional printing or processed by a gas permeable steel.
- the present disclosure the
- the at least one shaped air path 302 includes at least one main air duct 3021 and a plurality of secondary air ducts 3022 .
- the at least one main air duct 3021 is disposed around the mold cavity 301 , and communicates with the at least one gas passage 402 .
- Each of the plurality of secondary air ducts 3022 is arranged at the intervals between the main air duct 3021 and the mold cavity 301 .
- One end of each of the plurality of secondary air ducts 3022 communicates with the main air duct 3021 and the other end thereof is connected to the mold cavity 301 .
- the above embodiment of the present disclosure does not limit the structure of the at least one air path 302 .
- the lower mold base 40 includes at least one cooling waterway 403 .
- the at least one cooling circuit 303 of the lower mold 30 is connected to the at least one cooling waterway 403 of the lower mold base 40 .
- the at least one cooling waterway 403 communicates with the liquid device 54 .
- An internal cooling liquid (not shown) circulates inside the at least one cooling waterway 403 and the at least one cooling circuit 303 so as to maintain the lower mold base 40 and the lower mold 30 within a predetermined temperature value.
- the present disclosure further includes a control device 50 .
- the control device 50 controls an amount and timing of incoming and outgoing gases, and also adjusts the pressure in the mold cavity 301 .
- the injection molding machine 52 is also controlled by the control device 50 to control a flow of the raw material into the mold cavity 301 .
- a valve 56 for preventing backflow of the gas is provided between the control device 50 and the at least one gas passage 402 , so as to change the pressure in the mold cavity 301 .
- the present disclosure further includes a pressure measuring unit 53 .
- the pressure measuring unit 53 is electrically connected to the control device 50 , and senses the internal pressure of the mold cavity 301 . Therefore, the control device 50 is able to adjust the pressure in the mold cavity 301 at any time according to the data change of the pressuring measuring unit 53 , so as to keep it within a preset value.
- the control device 50 controls the gas device 51 to pre-inject gas through the at least one gas passage 402 the at least one shaped air path 302 to maintain a preset pressure inside the mold cavity 301 , thereby forming a back pressure state.
- the gasket groove 202 is disposed around the ejection port 201 ; that is, the gasket 203 can be disposed in the gasket groove 202 , and is attached to the upper mold 20 and the lower mold 30 , so as to keep a closed space when the upper mold base 10 is aligned with the lower mold base 30 . Therefore, the pressure in the mold cavity 301 can be controlled so that the gas leakage can be effectively prevented.
- the control device 50 adjusts the flow rate of gas according to the pressure data detected by the pressure measuring 53 .
- the gas is gradually withdrawn from the mold cavity 301 so that the gravitational force is generated inside the mold cavity 301 and the entrapped air phenomenon does not occur.
- the lower mold base 40 is separated from the upper mold base 10 .
- the control device 50 controls the gas to overflow from the at least one gas passage 402 through the at least one shaped air passage 302 and the plurality of pores, thereby separating the finished product from the mold cavity 301 .
- the present disclosure can automatically release the finished product without spraying the release agent in the mold cavity, and does not require any additional removal device. As such, the forming process can be shortened according to the present disclosure.
- FIG. 7 shows a block diagram of the injection molding device according to the present disclosure.
- the control device 50 controls a gas device 51 , an injection unit 52 , a pressure measuring unit 53 and a liquid device 54 , a mold 55 and a valve 56 .
- the mold 55 refers to a state in which the upper mold base 10 , the upper mold 20 , the lower mold base 40 and the lower mold 30 are combined.
- the control device 50 controls the amount of incoming and outgoing gases, the program and the time, and adjusts the pressure in the mold cavity 301 .
- the gas can be evacuated through the at least one shaped air path 302 .
- the pressure in the mold cavity 301 is lower than a preset value, the pressure in the mold cavity 301 can also be increased by the control device 50 , thereby maintaining a certain pressure in the mold cavity 301 .
- the back pressure state is mainly for the finished product with a smooth surface.
- the gas generates resistance to the injected mixture raw material, so that the surface of the injected mixture raw material forms a mutual resistance with the gas, and is squeezed to form a smooth surface.
- the control device 50 controls the pressure to naturally overflow or withdraw.
- the raw material required for the shoe pad is relatively soft, thereby maintaining the pressure between 7 bar and 9 bar in the mold cavity; if the present disclosure is used to make a snow frame, the raw material required for the snow frame is relatively hard, thereby probably maintaining the pressure between 60 bar and 70 bar in the mold cavity (the pressure value will be set according to the product properties). Therefore, when the manufactured products are different, the pressure range in the mold cavity is generally set between 2 bar and 100 bar, but not limited to the present disclosure.
- step S 81 mounting a forming mold on an injection molding machine, wherein the forming mold comprising: an upper mold base, a lower mold base, an upper mold and a lower mold, wherein the upper mold base has an injection port, the upper mold is arranged inside the upper mold base and has an ejection port, a gasket groove and a gasket, the lower mold base has at least one gas passage, the lower mold is arranged inside the lower mold base, and has a mold cavity and at least one shaped air duct, the lower mold is a porous material and the porous material enables the lower mold to have a plurality of pores; step S 82 : pre-injecting gas into the interior of the mold cavity to form a back pressure state; step S 83 : pouring a raw material into the injection molding machine, mixing the raw material with nitrogen or carbon dioxide of supercritical fluid and injecting the raw material into the
- the injection molding machine in step S 81 is especially a MUCELL micro-foaming injection molding machine or a chemical-foaming injection molding machine, but is not used to limit the type of the injection molding machine.
- the finished product formed by the MUCELL micro-foaming injection molding machine or the chemical-foaming injection molding machine together with the injection molding machine of the present disclosure has no bubble holes on the surface thereof and the inside thereof is more finely foamed. Therefore, according to the present disclosure, the entrapped air phenomenon does not occur in order to facilitate the shape integrity of the finished product.
- the injection molding device and the injection molding method according to the present disclosure have the following advantages: 1. the surface of a finished product is smooth, for example, a smooth shoe sole and a smooth shoe pad; 2. the strength and shock resistance of a finished product can be increased, because the overall foaming of a finished product is uniform as compared with the conventional technology; 3. the entrapped air problem can be effectively resolved; 4. the process steps can be saved a lot, so that the manufacturing time of a product can be shortened; and 5. production capacity is increased and costs are saved, so as to achieve energy saving and carbon reduction.
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Abstract
Description
- The present disclosure relates to an injection molding device.
- The injection molding machine, also known as an EVA injection machine or an injection machine, is a device or a machine that is mainly used to manufacture a plastic product. The injection molding machine is composed of two main parts: a clamping unit an injection unit.
- However, it is generally known that thermoplastic polyurethanes (TPU) raw materials must be subjected to a baking process to remove moisture contained. Water vapor will cause bubbles to be generated on the surface of a finished product when the raw materials are formed in the mold. Physical foaming will also have the same situation, which will result in a rough surface of a finished product. The initial embryo after foaming is subjected to surface processing to overcome the aforementioned problems, thereby increasing the process steps.
- Moreover, the abovementioned injection molding method allows the raw materials to be injected into the mold to be heated and foamed. The gas pressure in the mold is not consistently controlled so that the gas and the raw materials cannot be completely fused/merged or separated during the faming process, thereby causing the finished product to have the problems of partial hard blocks and uneven foaming. Moreover, when the raw materials are continuously injected into the interior of the mold and the mold is not effectively exhausted, this will cause incomplete filling and foaming porosity, which are commonly known as the entrapped air phenomenon. Such phenomenon will increase the defective rate of the finished products.
- In addition, in order to facilitate the removal of the finished products from the mold, the conventional methods are to spray the release agent in the mold to prevent the molding material from adhering to the inner wall of the mold. A removing device for taking out the finished products from the mold is provided. However, the release agent may remain on the inner wall of the mold, and will affect the subject process steps. Further, the spraying and the subsequent clearing operations are required. As such, how to provide a better injection molding device and a better injection molding method thereof has become one of the important issues.
- It is a primary object of the present disclosure to provide an injection molding device, so that the surface of a finished product is smooth and the entrapped air phenomenon can be improved. Therefore, the process can be shortened.
- Moreover, another object of the present disclosure is to provide an injection molding method, so that the raw materials do not need to be dried and the time for front work can be saved.
- In order to achieve the above objective, the present disclosure provides an injection molding device, an upper mold base, having an upper mold base groove and an injection port, wherein the injection port is connected to the injection molding machine; an upper mold, arranged inside the upper mold base groove and having an ejection port, a gasket groove and a gasket, wherein the ejection port is connected to the injection port; a lower mold base, operatively aligning or separating from the upper mold base and having a lower mold base groove and at least one gas passage, wherein the at least one gas passage allows gas to enter and exit; and a lower mold, arranged inside the lower mold base groove and having a mold cavity, wherein the lower mold together with the lower mold base aligns and separates from the upper mold together with the upper mold base, the lower mold includes at least one shaped air path that is connected to the mold cavity and the at least one gas passage, the lower mold is a porous material, the porous material enables the lower mold to have a plurality of pores; when the lower mode base is aligned with the upper mold base, the interior of the mold cavity is pre-injected with gas through the at least one gas passage and the at least one shaped air path to maintain a predetermined pressure inside the mold cavity; when a raw material in the injection molding machine enters the mold cavity during a forming process, the gas is gradually released from the mold cavity by controlling a rate, so that the raw material completely fills the mold cavity; when a finished product is formed in the mold cavity and the lower mold base is separated from the upper mold base, the gas is ejected from the at least one gas passage through the at least one shaped air path to the plurality of pores, so that the finished product is separated from the mold cavity.
- Preferably, the present disclosure further includes a control device, controlling an amount and timing of incoming and outgoing gases and adjusting the pressure in the mold cavity, wherein the injection molding machine is controlled by the control device to control a flow of the raw material into the mold cavity.
- Preferably, the upper mold is a porous material; the porous material enables the upper mold to have a plurality of pores.
- Preferably, the at least one shaped air path of the lower mold is formed by three-dimensional printing or processed by a gas permeable steel.
- Preferably, the at least one shaped air path includes at least one main air duct and a plurality of secondary air ducts, the at least one main air duct is disposed around the mold cavity and the bottom thereof, and communicates with the at least one gas passage, each of the plurality of secondary air ducts is arranged at the intervals between the main air duct and the mold cavity, and one end of each of the plurality of secondary air ducts communicates with the main air duct, the other end thereof is connected to the mold cavity.
- Preferably, the gasket groove is disposed around the ejection port, the gasket is disposed in the gasket groove, one side of the gasket is fitted to the bottom of the gasket groove, and another side of the gasket is attached to the lower mold when the lower mold base is aligned with the upper mold base.
- Preferably, the upper mold base and the lower mold base further include at least one cooling waterway.
- Preferably, a valve for preventing backflow of the gas is provided between the control device and the at least one gas passage.
- Preferably, the present disclosure further includes a pressure measuring unit, sensing the internal pressure of the mold cavity and is electrically connected to the control device.
-
FIG. 1 shows an exploded perspective view of an injection molding device according to a preferred embodiment of the present disclosure. -
FIG. 2 shows a schematic diagram of the injection molding device according to the preferred embodiment of the present disclosure. -
FIG. 3 shows a partial enlarged schematic diagram of the injection molding device shown inFIG. 2 according to the preferred embodiment of the present disclosure. -
FIG. 4 shows a stereoscopic diagram of a lower mold of the injection molding device according to the preferred embodiment of the present disclosure. -
FIG. 5 shows an A-A sectional view ofFIG. 2 according to the preferred embodiment of the present disclosure. -
FIG. 6 shows a B-B sectional view ofFIG. 2 according to the preferred embodiment of the present disclosure. -
FIG. 7 shows a block diagram of the injection molding device according to the preferred embodiment of the present disclosure. -
FIG. 8 shows a flow chart of an injection molding method according to the preferred embodiment of the present disclosure. - The detailed description of the present disclosure is provided in combination with the accompanying drawings.
- Referring to
FIGS. 1-7 , according to a preferred embodiment of the present disclosure, an injection molding device of the present disclosure for use with an injection molding machine, more particularly, a MUCELL micro-foam injection molding machine or a chemical-foam injection molding machine, mainly includes anupper mold base 10, anupper mold 20, alower mold 30 and alower mold base 40. - One side of the
upper mold base 10 is a first matchingsurface 104. The first matchingsurface 104 has an uppermold base groove 101. Another side of theupper mold base 10 has aninjection port 102. Theinjection port 102 of theupper mold base 10 is connected to one end of theinjection molding machine 52. Theupper mold 20 is arranged inside the upper mold base groove, and has twoejection ports 201, agasket groove 202 and agasket 203. Each of theejection ports 201 is connected to theinjection port 102. In an embodiment of the present disclosure, theupper mold 20 has two ejection ports, but they are not limited to the present disclosure. The material of theupper mold 20 is a porous material and the porous material enables theupper mold 20 to have a plurality of pores. In addition, theupper mold base 10 also includes at least onecooling waterway 103 and theupper mold 20 also includes at least one cooling circuit that is connected to the at least onecooling waterway 103 of theupper mold base 10. Referring toFIG. 7 , the at least onecooling waterway 103 is connected to a liquid device. The internal cooling liquid (not shown) is circuited inside the at least one cooling waterway and the at least one cooling circuit, thereby maintaining theupper mold base 10 and theupper mold 20 within a predetermined temperature value. Moreover, theupper mold 20 includes agasket groove 202 that is arranged around theejection port 201. Agasket 203 is disposed inside thegasket groove 202. One side of thegasket 203 is attached to the bottom of thegasket groove 202. - One side of the
lower mold base 40 is a secondmatching surface 404, and operatively aligns or separates from the first matchingsurface 104 of theupper mold base 10. The second matchingsurface 404 has a lowermold base groove 401 and at least onegas passage 402. The at least one gas passage is used for gas (not shown) in and out of agas device 51. Thelower mold 30 is a porous material. The porous material enables thelower mold 30 to have a plurality of pores. Thelower mold 30 is aligned with and is separated from theupper mold 20. Thelower mold 30 is arranged inside the lowermold base groove 401. Thelower mold 30 includes amold cavity 301 and at least one shapedair path 302. The present disclosure does not limit the manner in which the at least one shapedair path 302 of thelower mold 30 is formed. Preferably, the at least one shapedair path 302 of the lower mold is formed by three-dimensional printing or processed by a gas permeable steel. In an embodiment of the present disclosure, the - In the preferred embodiment of the present disclosure, the at least one shaped
air path 302 includes at least onemain air duct 3021 and a plurality ofsecondary air ducts 3022. The at least onemain air duct 3021 is disposed around themold cavity 301, and communicates with the at least onegas passage 402. Each of the plurality ofsecondary air ducts 3022 is arranged at the intervals between themain air duct 3021 and themold cavity 301. One end of each of the plurality ofsecondary air ducts 3022 communicates with themain air duct 3021 and the other end thereof is connected to themold cavity 301. The above embodiment of the present disclosure does not limit the structure of the at least oneair path 302. - Moreover, the
lower mold base 40 includes at least onecooling waterway 403. The at least onecooling circuit 303 of thelower mold 30 is connected to the at least onecooling waterway 403 of thelower mold base 40. Referring toFIG. 7 , the at least onecooling waterway 403 communicates with theliquid device 54. An internal cooling liquid (not shown) circulates inside the at least onecooling waterway 403 and the at least onecooling circuit 303 so as to maintain thelower mold base 40 and thelower mold 30 within a predetermined temperature value. - Referring to
FIG. 7 , the present disclosure further includes acontrol device 50. Thecontrol device 50 controls an amount and timing of incoming and outgoing gases, and also adjusts the pressure in themold cavity 301. Theinjection molding machine 52 is also controlled by thecontrol device 50 to control a flow of the raw material into themold cavity 301. In addition, avalve 56 for preventing backflow of the gas is provided between thecontrol device 50 and the at least onegas passage 402, so as to change the pressure in themold cavity 301. Moreover, the present disclosure further includes apressure measuring unit 53. Thepressure measuring unit 53 is electrically connected to thecontrol device 50, and senses the internal pressure of themold cavity 301. Therefore, thecontrol device 50 is able to adjust the pressure in themold cavity 301 at any time according to the data change of thepressuring measuring unit 53, so as to keep it within a preset value. - According to the present disclosure, when the
lower mold base 40 is aligned with theupper mold base 10, thecontrol device 50 controls thegas device 51 to pre-inject gas through the at least onegas passage 402 the at least one shapedair path 302 to maintain a preset pressure inside themold cavity 301, thereby forming a back pressure state. Referring toFIG. 1 , it is worth mentioning that thegasket groove 202 is disposed around theejection port 201; that is, thegasket 203 can be disposed in thegasket groove 202, and is attached to theupper mold 20 and thelower mold 30, so as to keep a closed space when theupper mold base 10 is aligned with thelower mold base 30. Therefore, the pressure in themold cavity 301 can be controlled so that the gas leakage can be effectively prevented. - According to the present disclosure, when the raw material of a gas and liquid mixture is injected into the
mold cavity 301 through theinjection port 102, the internal pressure of themold cavity 301 changes due to the injection of the raw material. Thecontrol device 50 adjusts the flow rate of gas according to the pressure data detected by the pressure measuring 53. When the raw material gradually fills themold cavity 301, the gas is gradually withdrawn from themold cavity 301 so that the gravitational force is generated inside themold cavity 301 and the entrapped air phenomenon does not occur. - Moreover, when a finished product (not shown) has been formed in the
mold cavity 301, thelower mold base 40 is separated from theupper mold base 10. Thecontrol device 50 controls the gas to overflow from the at least onegas passage 402 through the at least oneshaped air passage 302 and the plurality of pores, thereby separating the finished product from themold cavity 301. Compared with the prior art, the present disclosure can automatically release the finished product without spraying the release agent in the mold cavity, and does not require any additional removal device. As such, the forming process can be shortened according to the present disclosure. -
FIG. 7 shows a block diagram of the injection molding device according to the present disclosure. As shown inFIG. 7 , thecontrol device 50 controls agas device 51, aninjection unit 52, apressure measuring unit 53 and aliquid device 54, amold 55 and avalve 56. Themold 55 refers to a state in which theupper mold base 10, theupper mold 20, thelower mold base 40 and thelower mold 30 are combined. Thecontrol device 50 controls the amount of incoming and outgoing gases, the program and the time, and adjusts the pressure in themold cavity 301. When themold cavity 301 exceed the preset pressure, the gas can be evacuated through the at least one shapedair path 302. When the pressure in themold cavity 301 is lower than a preset value, the pressure in themold cavity 301 can also be increased by thecontrol device 50, thereby maintaining a certain pressure in themold cavity 301. - On the contrary, the back pressure state is mainly for the finished product with a smooth surface. The gas generates resistance to the injected mixture raw material, so that the surface of the injected mixture raw material forms a mutual resistance with the gas, and is squeezed to form a smooth surface. After the finished product is formed, the
control device 50 controls the pressure to naturally overflow or withdraw. - According to the preferred embodiments of the present disclosure, if the present disclosure is used to make a shoe pad, the raw material required for the shoe pad is relatively soft, thereby maintaining the pressure between 7 bar and 9 bar in the mold cavity; if the present disclosure is used to make a snow frame, the raw material required for the snow frame is relatively hard, thereby probably maintaining the pressure between 60 bar and 70 bar in the mold cavity (the pressure value will be set according to the product properties). Therefore, when the manufactured products are different, the pressure range in the mold cavity is generally set between 2 bar and 100 bar, but not limited to the present disclosure.
- In addition, as shown in
FIG. 8 , the present disclosure also provide an injection molding method, including the following steps S81-S85: step S81: mounting a forming mold on an injection molding machine, wherein the forming mold comprising: an upper mold base, a lower mold base, an upper mold and a lower mold, wherein the upper mold base has an injection port, the upper mold is arranged inside the upper mold base and has an ejection port, a gasket groove and a gasket, the lower mold base has at least one gas passage, the lower mold is arranged inside the lower mold base, and has a mold cavity and at least one shaped air duct, the lower mold is a porous material and the porous material enables the lower mold to have a plurality of pores; step S82: pre-injecting gas into the interior of the mold cavity to form a back pressure state; step S83: pouring a raw material into the injection molding machine, mixing the raw material with nitrogen or carbon dioxide of supercritical fluid and injecting the raw material into the mold cavity through the injection port; step S84: synchronously controlling an amount of gas in and out of the mold cavity while injecting the raw material, so that a pressure is maintained and controlled and at the end of the injection, all the pressure is controlled and released, thereby helping foam forming, so that the entrapped air phenomenon does not occur; and step S85: controlling the gas ejected from the at least one gas passage through the at least one shaped air path to the plurality of pores and automatically demolding a finished product. - According to the present disclosure, the injection molding machine in step S81 is especially a MUCELL micro-foaming injection molding machine or a chemical-foaming injection molding machine, but is not used to limit the type of the injection molding machine. The finished product formed by the MUCELL micro-foaming injection molding machine or the chemical-foaming injection molding machine together with the injection molding machine of the present disclosure has no bubble holes on the surface thereof and the inside thereof is more finely foamed. Therefore, according to the present disclosure, the entrapped air phenomenon does not occur in order to facilitate the shape integrity of the finished product.
- In summary, the injection molding device and the injection molding method according to the present disclosure have the following advantages: 1. the surface of a finished product is smooth, for example, a smooth shoe sole and a smooth shoe pad; 2. the strength and shock resistance of a finished product can be increased, because the overall foaming of a finished product is uniform as compared with the conventional technology; 3. the entrapped air problem can be effectively resolved; 4. the process steps can be saved a lot, so that the manufacturing time of a product can be shortened; and 5. production capacity is increased and costs are saved, so as to achieve energy saving and carbon reduction.
- Although the present disclosure has been described with reference to the preferred exemplary preferred embodiments thereof, it is apparent to those skilled in the art that a variety of modifications and changes may be made without departing from the scope of the present disclosure which is intended to be defined by the appended claims.
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Also Published As
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TWI660834B (en) | 2019-06-01 |
US10576669B2 (en) | 2020-03-03 |
CN110625891A (en) | 2019-12-31 |
TW202000427A (en) | 2020-01-01 |
CN110625891B (en) | 2021-06-22 |
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